Disposable multicup container

ABSTRACT

A collapsible, disposable beverage container  10  holds an insulating sleeve  12  that carries a collapsible bag  14  for holding hot fluid. The container  10  is made of paperboard. Preferred materials for the collapsible bag are nylon and metalized flexible materials. The entire structure  10  is formed from a single sheet of paperboard that is suitably scored, cut, bent and folded to a hex-shaped structure. The structure  10  includes seven panels  20 - 26  that form a six sided hexagonal structure. The two longest panels  23 - 24  overlap. The container has a top  30  that is integral with one of the longest panels. The container has a bottom  50  that includes multi-lobed interfering flaps  52, 62 . Those flaps are mirror images of each other and are mounted on the bottom edges of the panels. The panels have different lengths to provide a sloped upper surface. All of the panels have their lower edges in a continuous line.  
     At one end the bag is a narrow neck  16  with a threaded connection for receiving a threaded cap  17 . The other end has a folded gusset plate, not shown. Insulating material  12  surrounds the bag and may be any suitable material including polystyrene or any open or closed cellular material. As an alternative, the insulating sleeve  12  could be replaced by loose insulation or other suitable material for reducing the transfer of heat from the hot liquids contained in the bag  14  to the ambient environment.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of the filing date of U.S.provisional patent application Serial No. 60/385,289 filed Jun. 3, 2002.

[0002] This invention relates in general to containers and moreparticularly to disposable carafes that hold more that one serving of abeverage.

[0003] Consumers have a wide variety of choice of brewed coffee and tea.Coffee shops, convenience stores and even grocery stores offer manychoices of brewed coffee. A customer who wants to bring one or morechosen, brewed beverages to another location needs a portable containerto carry the coffee. Durable containers are expensive and many consumersprefer a less expensive, disposable container that would hold multiplecups of the beverage.

[0004] Others have attempted to meet this need by providing disposablecontainers that hold large quantities of coffee or tea in an inexpensiveand disposable container. One such container is hex-shaped and normallyrests on its side. See U.S. Pat. No. 6,209,781. It has an integralhandle that adds to the complexity of its manufacture and assembly. Whenit is first filled, the container may be unstable given the hex-shapedsides. Another container is shown in U.S. Pat. No. 5,715,992. It alsohas an integral handle. Both of the above containers provide dischargeopenings that are on the side of the container. In one or both cases thecoffee in the container is normally held in by a cap on an internalflexible bag that is filled with liquid. The cap is below the level ofthe coffee in the filled container. As such, in their normal positions,the containers may leak. Other multisided (hexagonal) containers arefound in U.S. Pat. Nos. 5,050,775; 5,531,375; and 4,418,861.

[0005] In a departure from the cardboard, knock-down containers, stillothers have proposed a container with a rigid, central frame having arectangular center section, a base, an integral spout and handle allmade of plastic. See, for example 6,375,040. The frame supports abeverage bag that is enclosed by two pieces of insulating cardboard. Thecontainer resembles a watering can. The bag is inserted into the frameand the bag is enclosed with the cardboard covers. The frame supportsthe weight of the filled beverage bag.

SUMMARY

[0006] The invention solves the problems of the prior art by making acontainer that is more stable, less likely to leak and pours from anupright position. In its broader aspects the invention provides a liquidcontainer for holding a relatively large quantity of liquid. It is madefrom a single sheet of paperboard, cardboard of other suitable materialand is operable to form from a collapsed, flat storage configuration toan upright configuration. The container has sidepanels and end panelsfor holding a beverage bag and for dispensing fluid from the bag.

[0007] The container is prepared from elongated paperboard that isdivided into multiple panels and end flaps that extend from one or moreof the panels to interlock and form end panels. The panels between theends of the paperboard are attached to adjacent panels along their edgesby an integral hinged portion of the paperboard to form a continuousmultisided sided structure. A front panel has a first end flap with anopening for receiving a neck of a beverage bag. Two end panels overlapeach other to surround a beverage bag. One of the end panels has asecond end flap with an opening aligned with the opening the first endflap for receiving the neck of the beverage bag. Inside the container isa flexible bag with a narrow neck for receiving and discharging abeverage. The bag is normally collapsed and expands to receive and holda beverage. Around the bag is an insulation sheath for keeping thebeverage at a stable temperature or otherwise reducing heat transfer toor from the beverage.

[0008] The end panels have openings in their sidepanels and thoseopening are aligned with each other. The user may insert a finger orthumb into the opening to assist in pouring the beverage from thecontainer. Two of the side panels have openings for receiving oppositeends of a handle. The panels may be an odd or an even number. Where theyare an odd number, the preferred number is five, seven or nine. Becausethe two end panels overlap, the number of sides in the final structurewill be one less than the total number of panels.

[0009] For an odd number of panels (and an even number of sidepanels)the invention provides a center panel that is shortest in length; theend panels are longest. The base edges of the panels lie in a line withone another. The top edges of the panels between the center panel andthe end panels line along a line connecting the edge of the center panelto the edge of the end panel. The center and the intermediate panelshave the same width and one end panel has a width smaller than the otherend panel in order to allow one end panel to overlap the other.

[0010] One of the end panels has a top end flap with six sides and threeears disposed on the edges of the three sides for folding into thecontainer. Most of the panels have bottom flaps disposed along theirrespective bottom edges for interlocking to form a bottom end panel. Thepanels adjacent to the center panel have top end flaps for cooperatingwith the center end flap to cover the top of end of the container.

[0011] The invention provides a new multi-cup insulated coffeecontainer. The invention is used to hold and keep warm multiple cups ofcoffee, including at least 12 eight ounce cups for a total of 96 fluidounces.

[0012] The invention addresses a long felt need in the area ofdisposable, insulated coffee containers that hold large quantities ofcoffee. Such containers are highly desired by individuals who bringcoffee to multiple coffee drinkers as well as by coffee retailers whorequire a disposable container for distributing large quantities ofbrewed coffee.

DRAWINGS

[0013]FIG. 1 is an elevation view of the structure.

[0014]FIG. 2 is a rear elevation view of the structure.

[0015]FIG. 3 is a planned view off the top of the container.

[0016]FIG. 4 is a planned view of an opened container top.

[0017]FIG. 5 is a planned view of a closed container bottom.

[0018]FIGS. 6 and 7 are planned views of opposite halves of thecontainer bottom closure.

[0019]FIG. 8 is a planned view of the top end flap.

DETAILED DESCRIPTION

[0020] The invention is a disposable container 10. Its structure isillustrated by FIGS. 1-8. Turning first to FIG. 8, there is shown across-sectional view of the invention. It includes an exteriorpaperboard container 10 that holds an insulating sleeve 12 that carriesa collapsible bag 14 for holding hot fluid. Bag 14 may be made of anysuitable material that can contain hot beverages. Preferred materialsfor the collapsible bag are nylon and metalized flexible materials. Atone end the bag is a narrow neck 16 with a threaded connection forreceiving a threaded cap 17. The other end has a folded gusset plate,not shown. An insulating sleeve 12 surrounds the bag and may be anysuitable material including polystyrene or any open or closed cellularmaterial. As an alternative, the insulating sleeve 12 could be replacedby loose insulation or other suitable material for reducing the transferof heat from the hot liquids contained in the bag 14 to the ambientenvironment.

[0021] The container 10 is made of paperboard. Paperboard has a (brown)or unfinished surface as well as a finished surface. The finishedsurface may have any suitable color. It is common that such paperboardhave a white finished surface. Paperboard is chosen in lieu ofcorrugated materials because paperboard is relatively stiffer and canform bent panels and integral hinges. The entire structure 10 is formedfrom a single sheet of paperboard that is suitably scored, cut, bent andfolded to provide the structure shown in the figures. The structure 10includes seven panels 20-26 that form a six sided hexagonal structure.The two longest panels 23-24 overlap. The container has a top 30 that isintegral with one of the longest panels. The container has a bottom 50that includes multi-lobed interfering flaps 52, 62. Those flaps aremirror images of each other and are mounted on the bottom edges of thepanels.

[0022] The panels have different lengths to provide a sloped uppersurface. All of the panels have their lower edges in a continuous line.Turning to FIG. 1, the shortest panel 20 faces the front of the device.Opposite front panel 20 are the back panels 23, 24. They are the longestpanels. Panels 21 and 26 are on opposite sides of panel 20 and theirrespective top edges generally slope in an upward direction towards therear. Panels 25 and 26 are integral, respectively, with panels 26 and21. The upper edges of panels 25, 22 also slope up toward to top edge ofthe back panels 23, 24. Panels 25 and 22 are integral with the rearpanels 23, 24, respectively. The rear panels 23, 24 overlap and aresuitably fixed together by adhesive materials such as glue or any othersuitable means including mechanical and chemical means for fixing one ofthe panels to the other. The rear panels 23, 24 have an aperture 18 thatprovides a thumb hole for carrying or manipulating the container.

[0023] Top flap 30 is integral with either the inside or the outsideback panels 23, 24. The top flap 30 has a central hexagonal planarsurface 31 that includes an opening 32 for the neck 16 of the bag 14.The top flap 30 has three integral lobes 44, 46 and 42 that are disposedon alternate sides of the hexagonal flap 31. Flaps 44 and 46 haveintegral hinges 45 that allow the outer flaps to bend and to fitadjacent top ends of panels 25, 22, respectively. The outer flaps 44, 46fold over retaining lobes 27 and 29 that are on the upper ends,respectively, of front slanted panels 26, 21. The retaining flaps 27, 29cover the top of the bag 14. The flaps 44 and 46 fold into the interiorof the container 10. Small cutouts 48, 49 along the integral hinge/scorelines 45, 47 serve to capture and lock onto the lobes 27, 29 of panels26, 21 when the flap 30 is closed. The front lobe 42 of the flap 31 fitsbehind front panel 20. Front panel 20 has an integral, hinged verticalcollar 34 with an opening 37 between a pair of yokes 36, 38. The yokes36, 38 press against the neck 16 of the bag 14 in order to secure thebag in the opening 32. The neck of the bag is smaller than the openingbetween the yokes. A retainer ring 80 on the neck is larger than theyoke opening and holds the neck in between the yokes.

[0024] Bottom 50 of the container 10 is formed by the opposingmulti-lobe structure shown in FIGS. 6 and 7. Turning first to multi-lobe52 there is shown a central lobe 53 that is integral with the frontpanel 20. A single lobe 54 is integral with front panel 21 and a doublelobe structure 55, 57 is integral with front panel 26. The double lobestructure 55, 57 is scored and bends along an integral hinge line 56.FIG. 7 shows a corresponding structure that is formed along the bottomof panels 22, 23 or 24, and 25. The lobe 57 is glued to opposite lobe 64and likewise lobe 67 is glued to opposite lobe 54. The central lobes 53and 63 have interference cuts and a meeting line for folding and lockingtogether to provide the bottom surface of the container.

[0025] With reference to FIG. 4, the container 10 is collapsed bybending the front panel toward the back panel. In particular, the threefront side panels collapse onto the three back side panels. Bottom foldsinto the collapsing container volume by bending along the line B asshown in FIG. 4. The line B comprises creases in the end lobes 65/67 and55/57. The center portion of the line is the mating line of lobes 53 and63.

[0026] To manufacture the container 10, a single paperboard sheet issuitably scored, punched and bent to provide the apertures, lobes andintegral hinges described above. Then the rear panels 23, 24 are gluedtogether as are the bottom lobes 64/57 and 54/67. At that stage, theentire assembly may be stored in a flattened state until it is ready foruse. When required, the structure is manipulated to expand and to lockthe bottom lobes 53, 63 into place. A suitable insulating sleeve 12 isadded inside of the container and a collapsible bag 14 is place insidethe insulating sleeve 12. The top flap 30 is folded over the neck 16 ofthe bag 14. The collar 34 is also folded over the neck in order to formthe final structure. The cap 17 on the bag may be removed from the bagmay be filled with hot beverage such as coffee or hot tea or hot cocoaor any other suitable hot or even cold beverage. After filling the bag14, cap 17 is screwed back onto the neck 16 and the customer may takethe disposable beverage container from the retail establishment.

[0027] With the invention the container must be tipped from its uprightposition in order to dispense fluid. The relative vertical orientationof the container coupled with its wide base, provides a stable, uprightcontainer. A user must not only open the cap sealing the flexible bag,but must also tip the container. As such, at least two affirmativeactivities are required before the container dispenses fluid. Thisconstruction and arrangement overcomes disadvantages of prior artdevices that rely upon gravity for dispensing fluid. Those devices placethe discharge spout proximate the bottom of the container. With suchdevices fluid may be accidentally dispensed if someone opens the cap. Incontrast, the invention places the discharge spout far away from thebottom of the container and put it on the top sloping panel therebyminimizing the possibility of accidentally pouring hot coffee.

[0028] Having thus described the preferred embodiment of the invention,those skilled in the art will appreciate that other modifications,changes and variations may be made including omissions and additions offurther structures without departing from the spirit and scope of theinvention. For example, the invention shows a six-sided structure thatincludes seven panel pieces. Those skilled in the art will appreciatethat other multisided structures may be made where the numbers of panelpieces exceed the number of sides by one or more. The panel can be madestronger by using heavier paperboard or by making a blank with morepanels that overlap.

[0029] The dimensions, angles and radii of curvature shown in thefigures is an example of a paperboard container suitable for holding 98ounces of beverage. Those skilled in the art will understand that thedimensions, angle and radii may be altered to make larger or smallercontainers.

What we claim is:
 1. A liquid container for holding a relatively largequantity of liquid and operable to deform from a collapsed, flat storageconfiguration to an upright configuration with sidepanels and end panelsfor holding and dispensing fluid, the container comprising: a containerstructure comprising an elongated paperboard divided into multiplepanels that form sidepanels and flaps extending from one or more of thepanels for forming end panels; wherein panels between the ends of thepaperboard are attached to adjacent panels along their edges by anintegral hinged portion of the paperboard to form a continuousmultisided sided structure, a front panel has a first end flap with anopening for receiving a neck of a beverage bag; two end panels foroverlapping each other to surround a beverage bag and having a secondend flap with a opening aligned with the opening the first end flap forreceiving the neck of the beverage bag; a flexible bag disposed insidethe container panel having a narrow neck for receiving and discharging abeverage and expandable when filled with a liquid from a collapsedposition to an enlarged position for holding fluid; and an insulationsheath surrounding the flexible bag for reducing the transfer of heatbetween the fluid in the bag and ambient environment.
 2. The containerof claim 1 wherein the end panels have openings in their sidepanelsaligned with each other for admitting a digit of a user to assist inpouring the beverage from the container.
 3. The container of claim 1wherein two side panels have openings for receiving opposite ends of ahandle.
 4. The container of claim 1 wherein the panels are an odd or aneven number.
 5. The container of claim 4 wherein the container comprisesan odd number and the odd number is five or seven or nine.
 6. Thecontainer of claim 1 wherein the panels have an odd number with a centerpanel being shortest in length and the end panels being longest.
 7. Thecontainer of claim 6 wherein the base edge of the panels lie in a linewith one another.
 8. The container of claim 7 wherein the top edges ofthe panels between the center panel and the end panels line along a lineconnecting the edge of the center panel to the edge of the end panel. 9.The container of claim 6 wherein the center and the intermediate panelshave the same width.
 10. The container of claim 6 wherein one end panelhas a width smaller than the other end panel in order to allow one endpanel to overlap the other.
 11. The container of claim 6 wherein thecenter panels has a top end flap with six sides and ears disposed on theedges of the three sides for folding into the container.
 12. Thecontainer of claim 6 wherein selected panels have bottom flaps disposedalong their respective bottom edges for interlocking to form a bottomend panel.
 13. The container of claim 6 wherein the panels adjacent thecenter panel have top end flaps for cooperating with the center end flapto cover the top of end of the container.
 14. The container of claim 6wherein the two end panels adhere to each other to form a six sidedcontainer.
 15. A liquid container for holding a relatively largequantity of liquid and operable to deform from a collapsed, flat storageconfiguration to an upright configuration for holding and dispensingfluid, the container comprising: a container structure comprising anelongated paperboard divided into seven rectangular panels that formsidepanels and flaps that form end panels, wherein the panels betweenopposite ends of the paperboard are attached to adjacent panels alongtheir longer side by an integral hinged portion of the paperboard toform a continuous six sided structure; the center panel being one of theshortest of the seven panels, an end panel being one of the longest ofthe panels and two panels on both sides of the center panel havinglengths greater than the center panel and less than the one longest endpanel; the one longest end panel having at one end at least one coverflap with six sides for forming a top cover of the container that slopesfrom the one longest end panel to the center shortest panel, the coverflap having an opening; the panels having bottom flaps at their endsopposite the top flap for forming a bottom floor of the uprightcontainer; a flexible bag disposed inside the container panel andexpandable from a collapsed position to an enlarged position for holdingfluid and a neck located the top of the bag for extending through anopening in the top sloping panel to receive and discharge beverages; aninsulation sheath surrounding the flexible bag for reducing the transferof heat between the fluid in the bag and ambient environment; whereinthe upright container has a height greater than the width of its baseand the container is tilted from its normal upright position fordispensing fluid from the flexible bag.
 16. The container of claim 15wherein the other end panel adheres to the one longest end panel to forma six sided container.
 17. The container of claim 15 having a secondopening in the two end panels for providing access for a finger and ahandle extending from one intermediate panel to an opposite intermediatepanel.